Sunshade system using linear actuators and free-floating canopy

ABSTRACT

A shade system includes a first linear actuator attachable to a structure, and a second linear actuator spaced from the first linear actuator and attachable to the structure. The first and second linear actuators are each displaceable between a retracted position and an extended position. A canvas connected between the first and second linear actuators is fixed to distal ends and to proximal ends of the first and second linear actuators and is free-floating between the distal and proximal ends. The canvas is configured to retract into an accordion configuration when the first and second linear actuators are displaced from the extended position to the retracted position.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 63/087,536, filed Oct. 5, 2020, the entire contentof which is herein incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

(NOT APPLICABLE)

BACKGROUND

The invention relates to a shade system for a marine vessel or the likeand, more particularly, to a lower cost single stage automated shadesystem.

Existing shade systems with multiple linear actuators are not able toaccommodate relative motion between the various actuators. As such,these systems tend to incorporate advanced electronic control systems(e.g., PCBs) to ensure that the actuators remain aligned. Furthermore,such systems tend to rely on PCBs or the like to detect obstructionsthrough monitoring of current draw. These systems tend to be expensiveand have multiple potential failure points that can affect systemreliability.

During high-speed transport, shade systems are typically stowed to avoiddamage to the shade system and also prevent wind effects on the vessel.External storage boots have been used to cover stowed shade systems. Anexternal storage boot is a separate piece of fabric with attachmentstructures. These components are wrapped around slack canvas and securedfor system transport. Issues with these systems include the externalboot being lost, the need to store the boot when the system is beingutilized, costs associated with additional components, and difficultyinstalling the external boot (requiring multi-person operation in manycases).

Roller assemblies are spring-loaded or gear-driven structures thatspiral wind the canvas for storage during retraction of the system.These assemblies are labor intensive during manufacture and havemultiple potential points of failure during usage. They also tend to beheavy, which can be problematic on small marine vessels with center ofgravity concerns.

It may be desirable to attach tubular constructs of a shade system tovarious existing mounting structures on the vessel. Existing solutionshave singular sizing constraints, which means that a specific product isrequired for each mounting configuration (e.g., different diameter tube,tubular vs flat, etc.). Existing solutions lack adjustability and oftenrequire significant effort be devoted to measuring and marking prior toinstallations. Moreover, installation of these systems is generally amulti-person job.

Existing shade systems typically include telescoping or scissor-stylesystems to extend and retract a canvas shade. Existing systems, however,only allow for canvas tensioning in two directions. Furthermore, thesesystems require fixed mounting locations. This creates difficulties forboth OEM and A/M installations requiring precise tolerancing andacquisition of specific components.

It may be desirable to attach a shade system to existing structure(s) ona vessel such as T-tops, radar arches and the like. Current systems,however, are typically assembled to the existing structure via the useof various clamps and mounting hardware. This increases system cost andlabor requirements and allows for systems to be installed such that theactuators are misaligned, which can degrade system performance.

SUMMARY

It would be desirable to provide an automated shade system thatovercomes the drawbacks noted above with existing systems.

In some embodiments, the system of the described embodiments iscomprised of two motor driven linear actuators, a free-floating canvas,specialized mounting componentry, a wire harness, and a singular switchto actuate the system. There is no circuit board or chip controlling thesystem. The system is able to slightly “rack” if the actuators deploy orretract at different speeds. The actuators are self-aligning at the fulldeployment position and full retraction position.

A specialized canvas assembly may contain features allowing the canvasto wrap around itself, securing the fabric for high speed transport.Specifically, the canvas may incorporate a linear portion of fabric thatis able to compress into an “accordion” like structure. There is aseparate portion of the canvas comprised of a loop possessing opposingmale and female attachment structures (e.g., zippers, hook and loopfasteners, etc.). When the shade system is extended, the entire canvasis pulled taught against the framework members of the shade system. Whenthe system is retracted, the loop section of the canvas is able to bepulled around the “accordion” section of the canvas and is secured bythe attachment structures. This simulates a storage boot and allows forhigh speed transport of the system while preventing the canvas fromflapping or catching wind.

An attachment device may be provided to attach tubular constructs of theshade system to various existing mounting structures on the vessel. Insome embodiments, the attachment device is a clamp with a specialized“S” mounting structure, two clamping components, and hardware includingbolts and nuts. The assembly allows for tubular structures (e.g., linearactuators) to be attached to other tubular structures (e.g., T-topframes) with a variety of tubing outer diameters/shapes and/or to attachthe system to flat frameworks (e.g., hard tops).

In some embodiments, a telescoping awning system includes nestedcrossbars and a specialized canvas tensioning system to accommodatemultiple overall system widths as determined by the actuator mountinglocation. The nested crossbars allow for the canvas support structure toadapt to variable mounting locations. The canvas tensioning system iscomprised of webbing members rigidly affixed to the primary canvas andcam lock capable sliding members that ride on the actuator extensionarms. The webbing is tightened through the cam lock sliders allowing fora canvas with a fixed primary width to adapt to multiple actuatormounting widths.

In some embodiments, a telescoping shade system installs the stationarycomponents of the actuators directly within the tubular framework of aT-top structure. The system allows for reduced cost by removing externalmounting features, and direct integration into the T-top frame improvesthe retention and sturdiness of the system.

The shade system may be a telescoping linear actuator system with twolinear actuators attached via an extensible crossbar such that theattachment points of the crossbar are able to pivot, allowing forrelative motion between the two actuators. Furthermore, swivel eye endson the actuators are frictionally attached via controlled crimp featuresthat allow for rotary motion only when the actuators reach their end oftravel. The actuators possess current limiting devices that limit thetotal load output capability of the system.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects and advantages will be described in detail withreference to the accompanying drawings, in which:

FIG. 1 shows the shade system in a deployed position;

FIG. 2 shows the shade system in a retracted position;

FIG. 3 is a close-up view of the rings and strap configurationconnecting the canvas to the actuators;

FIGS. 4-6 show an embodiment including an integrated boot;

FIGS. 7-10 show mounting clips for attaching tubular constructs to amounting structure;

FIGS. 11 and 12 show a variable width telescoping awning system withprovisions for tensioning the canvas;

FIG. 13 shows an exemplary shade system integrated into a T-topstructure;

FIGS. 14 and 15 show an extensible crossbar with swivel eye ends; and

FIG. 16 is a close-up view of an actuator swivel eye end.

DETAILED DESCRIPTION

With reference to FIGS. 1 and 2, a shade system 10 is configured as asingle stage automated shade system intended to target lower-cost boatsin the recreational marine industry. The system 10 includes a firstlinear actuator 12 attachable to a structure S (e.g., a T-top, radararch, etc.). A second linear actuator 14 is spaced from the first linearactuator 12 and is similarly attachable to the structure S. In someembodiments, the first and second linear actuators 12, 14 are motordriven and are displaceable between a retracted position (FIG. 2) and anextended position (FIG. 1). The shade system 10 also includes astationary crossbar 11 connected between a proximal end of linearactuators 12, 14 and a driven crossbar 13 connected between a distal endof linear actuators 12, 14. See FIG. 4.

A canvas 16 is connected between the first and second linear actuators12, 14. The canvas 16 is fixed to distal ends and to proximal ends ofthe first and second linear actuators 12, 14 and is free-floatingbetween the distal and proximal ends. Using ring connectors as shown inFIG. 3, the canvas 16 is configured to retract into the accordionconfiguration shown in FIG. 2 when the first and second linear actuators12, 14 are displaced from the extended position to the retractedposition.

In some embodiments, the motor driven first and second linear actuators12, 14 are operable via a single switch. There is no circuit board orchip controlling the system. Rather, the system is able to slightly“rack” if the actuators 12, 14 deploy or retract at different speeds.The actuators 12, 14 are self-aligning at the fully extended positionand the fully retracted position.

With continued reference to FIG. 3, in some embodiments, the canvas 16is connected to the actuators 12, 14 via a ring 18 including a clip 20through which an adjustable strap 22 is secured. The strap 22 is sewn orotherwise connected to the canvas and subsequently extends through theclip 20. The clip 20 includes a cam lock portion that enables the strap22 to tension the canvas 16. The rings 18 fit loosely over the actuators12, 14 so that the canvas is free-floating between the distal andproximal ends of the actuators 12, 14.

With reference to FIGS. 4-6, the canvas 16 may be provided with featuresallowing a portion of the canvas 16 to wrap around itself, securing thefabric for high-speed transport. In this context, the canvas 16 may beprovided with a shade section 16 a and a cover section 16 b connected tothe shade section 16 a. Cover section 16 b is a circular piece of canvasfabric for loosely encompassing the stationary crossbar 11. In theextended position as shown in FIG. 4, the cover section 16 b may beextended over the cabin area or the like and contribute to the shadingfunction of the canvas 16. In the extended position, the stationarycrossbar 11 engages an exterior end of the cover section 16 b to pullthe canvas taut. When the canvas 16 is retracted into the accordionconfiguration (see FIGS. 2 and 5), the cover section 16 b is not part ofthe accordion configuration and can be pulled around the accordionconfiguration of the canvas 16 and secured by suitable attachmentstructures or connectors 24. In the retracted position, the coversection 16 b may be pulled so that the stationary crossbar 11 engages aninterior end of the cover section to allow the exterior end of the coversection to wrap around the accordion configuration. The cover section 16b may be provided with the connectors 24 at ends thereof. Exemplaryconnectors 24 may include a zipper as shown in FIG. 5, a hook and loopfastener, snaps, etc. As shown in FIG. 6, the connectors 24 are providedat both interior and exterior ends of the cover section 16 b, and whenthe canvas 16 is retracted into the accordion configuration, the coversection 16 b is looped over the accordion-configured shade section 16 ato engage the connectors 24. The cover section 16 b simulates a storageboot and allows for high-speed transport of the system while preventingthe canvas from flapping or catching wind.

The integrated boot canvas via the cover section 16 b is a low-costlightweight method of storing canvas when the shade system is not inuse. The integral nature of the cover section 16 b ensures that the bootfunctionality cannot be misplaced. Furthermore, the system is easilydeployed by a single individual.

FIGS. 7-10 show an exemplary clip 26 for attaching tubular constructs toan existing mounting structure. The clip 26 is provided with an S-shapedmounting structure, two clamping components, and hardware includingbolts and nuts. The clip 26 allows for tubular structures (e.g., linearactuators) to be attached to other tubular structures (e.g., T-topframes) with a variety of tubing outer diameters or shapes and/or toattach the shade system to flat frameworks (e.g., hard tops).

The clips 26 allow for a single product to cover nearly any conceivableinstallation scenario. Additionally, the system inherently includesadjustability to allow for rapid installation. The clips 26 are alsoreadily installed by a single person, as the S-shape of the clip 26allows for the top clamping component to balance on an upper tubularstructure without user support. The clips 26 can accommodate any sizeand shape of canopy frame. FIG. 10 shows the clips supporting one of thelinear actuators 12, 14 of the shade system 10.

FIGS. 11 and 12 show a variation including a variable width telescopingawning system with a specialized canvas tensioning system. Thetelescoping awning system includes nested crossbars 28 and a specializedcanvas tensioning system to accommodate multiple overall system widthsas determined by actuator mounting locations allowing for fourdirections of canvas tension. The nested crossbars 28 allow for thecanvas support structure to adapt to variable mounting locations.

The canvas tensioning system is comprised of webbing members 30 rigidlyaffixed to the canvas 16 and cam lock capable sliding members 32 thatride on extension arms of the actuators 12, 14. The cam lock slidingmembers 32 slide on the actuators 12, 14 with a small amount ofclearance to allow for the sliding action. The webbing 30 is tightenedthrough the cam lock sliding members 32, allowing for a canvas with afixed primary width to adapt to multiple actuator mounting widths.

The configuration shown in FIGS. 11 and 12 allows for reduced complexityby providing a single part to accommodate multiple installations. Theadjustability of the system reduces the need for precise tolerancing andallows for the system to operate with less electrical power. The camlock sliding members 32 allow for four direction tensioning of canvasand hands-free stowage of the system during retraction.

FIG. 13 shows a variation with the shade system incorporated into thetubular framework TF of a T-top structure TS. The actuators 12′, 14′include a stationary component and a movable component. The stationarycomponents of the actuators 12′, 14′ are installed directly within thetubular framework TF of the T-top structure TS. The illustrated systemallows for reduced cost by removing external mounting features.Additionally, the direct integration into the T-top structure TSimproves retention and sturdiness of the system.

FIGS. 14-16 show a self-aligning load limiting linear actuator system.The linear actuators in this embodiment are attached via an extensiblecrossbar 34 such that the attachment points of the crossbar 34 are ableto pivot, allowing for relative motion between the two actuators. Canvas16 is generally attached to and travels with extensible crossbar 34, butis spaced from the extensible crossbar in FIGS. 14 and 15 for clarity.Swivel eye ends 36 on the actuators are frictionally attached viacontrolled crimp features that allow for rotary motion only when theactuators reach their end of travel. The swivel eye ends 36 are capableof rotation if needed. During normal operation, the friction between theswivel eye ends 36 and the extensible crossbar 34 is greater than thefriction between the lead screw and nut. At end of travel, the leadscrew and nut become locked together, but the motor is still attemptingto rotate. In this instance, the swivel eye ends 36 become stationary,and the tube is able to begin rotating. The benefit is that the motordoes not go into a stall condition. In this context, the actuatorspossess current limiting devices that limit the total load outputcapability of the system.

The construction allows for linear actuator systems to operate withoutthe need for PCB control. This vastly simplifies the system and reducescosts. The friction eye end mechanisms allow for linear load control viamechanical means. This increases safety by allowing for inherent currentlimiting and by limiting linear load capability in the event thatsomething becomes entangled in the system during switch operatedmovement.

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiments,it is to be understood that the invention is not to be limited to thedisclosed embodiments, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims.

1. A shade system comprising: a first linear actuator attachable to astructure; a second linear actuator spaced from the first linearactuator and attachable to the structure, the first and second linearactuators each being displaceable between a retracted position and anextended position; and a canvas connected between the first and secondlinear actuators, the canvas being fixed to distal ends and to proximalends of the first and second linear actuators and being free-floatingbetween the distal and proximal ends, wherein the canvas is configuredto retract into an accordion configuration when the first and secondlinear actuators are displaced from the extended position to theretracted position.
 2. A shade system according to claim 1, wherein thefirst and second linear actuators are motor driven.
 3. A shade systemaccording to claim 2, wherein the motors are operable via a singleswitch.
 4. A shade system according to claim 1, wherein the first andsecond linear actuators are self-aligning at the extended position andthe retracted position.
 5. A shade system according to claim 1, furthercomprising a plurality of rings secured over the first and second linearactuators, and a corresponding plurality of straps connected between therings and the canvas.
 6. A shade system according to claim 5, whereinthe straps are adjustable to adjust canvas tension.
 7. A shade systemaccording to claim 1, wherein the canvas comprises a shade section and acover section connected to the shade section, wherein the cover sectionis sized and positioned to cover the shade section when the canvas isretracted into the accordion configuration.
 8. A shade system accordingto claim 7, wherein the cover section comprises connectors at endsthereof, and wherein when the canvas is retracted into the accordionconfiguration, the cover section is positioned over the shade section toengage the connectors.
 9. A shade system according to claim 1, whereinthe structure comprises a T-top having a tubular framework, and whereinthe first and second linear actuators are installed within the tubularframework.
 10. A shade system according to claim 9, wherein each of thefirst and second linear actuators comprises a stationary component and alinearly displaceable component, and wherein the stationary component issecured within the tubular framework.
 11. A shade system according toclaim 9, wherein the first and second linear actuators are motor driven.12. A shade system according to claim 1, wherein the structure comprisesa T-top having a tubular framework, the shade system further comprisinga first clip coupled with the first linear actuator and a second clipcoupled with the second linear actuator, the first and second clipsbeing configured to connect to the tubular framework of the T-top.
 13. Ashade system according to claim 1, further comprising a first clipcoupled with the first linear actuator and a second clip coupled withthe second linear actuator, the first and second clips being configuredto connect to the structure.
 14. A shade system according to claim 1,further comprising a canvas tensioning system including webbing membersaffixed to the canvas and cam lock sliding members coupled with thefirst and second linear actuators, wherein the webbing members aretightened via the cam lock sliding members.
 15. A shade system accordingto claim 1, further comprising a crossbar connected between distal endsof the first and second linear actuators and connected to the canvas,wherein attachment points between the crossbar and the first and secondlinear actuators are pivotable.
 16. A marine vessel including a cabinarea with a boat deck, the marine vessel comprising: a structural membersecured to the boat deck and extending over the cabin area; and a shadesystem attached to the structural member, the shade system comprising: afirst linear actuator connected to the structure; a second linearactuator spaced from the first linear actuator and connected to thestructure, the first and second linear actuators each being displaceablebetween a retracted position and an extended position; and a canvasconnected between the first and second linear actuators, the canvasbeing fixed to distal ends and to proximal ends of the first and secondlinear actuators and being free-floating between the distal and proximalends, wherein the canvas is configured to retract into an accordionconfiguration when the first and second linear actuators are displacedfrom the extended position to the retracted position.
 17. A marinevessel according to claim 16, wherein the canvas comprises a shadesection and a cover section connected to the shade section, wherein thecover section is sized and positioned to cover the shade section whenthe canvas is retracted into the accordion configuration.
 18. A marinevessel according to claim 16, wherein the structure comprises a T-tophaving a tubular framework, and wherein the first and second linearactuators are installed within the tubular framework.
 19. A marinevessel according to claim 16, wherein the structure comprises a T-tophaving a tubular framework, the marine vessel further comprising a firstclip coupled with the first linear actuator and a second clip coupledwith the second linear actuator, the first and second clips beingconfigured to connect to the tubular framework of the T-top.
 20. Amethod of installing a shade system on a marine vessel including astructure, the method comprising: attaching a first linear actuator tothe structure; attaching a second linear actuator spaced from the firstlinear actuator to the structure, the first and second linear actuatorseach being displaceable between a retracted position and an extendedposition; and connecting a canvas between the first and second linearactuators by fixing the canvas to distal ends and to proximal ends ofthe first and second linear actuators, wherein the canvas isfree-floating between the distal and proximal ends, wherein theconnecting step is practiced such that the canvas is configured toretract into an accordion configuration when the first and second linearactuators are displaced from the extended position to the retractedposition.